Warehouse automation systems and methods

ABSTRACT

A warehouse automation system adapted to improve warehouse operating productivity includes a plurality of carts for transporting products within a warehouse and a controller. The controller is adapted to associate a first one of the plurality of carts with a first person and to control the first cart to lead the first person around the warehouse. According to one advantage, the time the first person spends restocking, picking, counting, sorting, moving, and packing product into customer orders and shipments, for example, is reduced.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of and claims priority to and thebenefit of all of U.S. patent application Ser. No. 16/034,125, filedJul. 12, 2018, which is a continuation of U.S. patent application Ser.No. 15/812,287, filed Nov. 14, 2017, which is a continuation of U.S.patent application Ser. No. 15/371,590, filed Dec. 7, 2016, which claimspriority to and the benefit of U.S. Provisional Patent Application No.62/263,966, filed Dec. 7, 2015, the entire disclosures of all of whichare hereby incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

In various embodiments, the present invention relates to warehouseautomation systems and methods. In particular, the systems and methodsimprove warehouse operating productivity.

BACKGROUND

In general, warehouses are built to temporarily house products and toprovide access to those products for fulfilling future orders. Manuallabor is typically required to receive, store, count, pick, and ship theproducts for orders. Managing the capacity of the warehouse, thevariability of products, the availability of labor, and the expectationsof customers, while minimizing the costs of operations andtransportation, can be a challenge for warehouse operators. Manywarehouses employ some form of automation to reduce the dependency onlabor in the warehouse. These automation systems are generally limitedby the availability of open space, the time it takes to install thesystem, the size and weight of the products the system can support, andthe cost to purchase and install the system. The installation of thesesystems may also further constrain the warehouse operator and limit theability to meet changes in products, customer expectations, and costs.In addition, access to additional manual labor as business grows can bea significant problem, particularly for operators supporting industriesthat are highly seasonal.

Accordingly, a need exists for systems and methods of improvingwarehouse operating productivity.

SUMMARY OF THE INVENTION

In various embodiments, the warehouse automation system described hereinfacilitates the movement of product around a warehouse and reduces thetime associates spend restocking, picking, counting, sorting, moving,and packing product into customer orders and shipments. This helpswarehouse operators use less labor and move product around the warehousefaster.

In general, in one aspect, embodiments of the invention feature awarehouse automation system adapted to improve warehouse operatingproductivity. In one embodiment, the warehouse automation systemincludes a plurality of carts for transporting products within awarehouse and a controller. The controller is adapted to associate afirst one of the plurality of carts with a first person and to controlthe first cart to lead the first person around the warehouse.

Various embodiments of this aspect of the invention include thefollowing features. The controller may also be adapted to move the firstcart at a speed equal to a normal pace of the first person, to move thefirst cart at a speed faster than a normal pace of the first person, toset settings of the first cart personal to the first person, to assign atask to the first person based upon a computed and/or stored ability ofthe first person, to associate a second one of the plurality of cartswith the first person at the same time that the first cart is associatedwith the first person, to associate the first cart with a second persondifferent from the first person at (optionally) the same time that thefirst cart is associated with the first person, and/or to set settingsof the first cart personal to the second person.

The first cart may include a receptacle for receiving a product and/or amotor for propelling the first cart. The first cart may also include anon-screen interface and/or an off-screen interface for communicatinginformation to the first person. For example, the on-screen interfacemay be adapted to communicate information concerning a physical locationof the first cart within the warehouse, a physical location of certainproduct within the warehouse, a current task assigned to the firstperson, time between various tasks, priorities in the warehouse, and/orperformance of the first person.

The off-screen interface may include lighting and/or an audio source.The lighting, for example, may be adapted to identify, throughillumination, a receptacle on the first cart within which a product isto be placed or from which a product is to be retrieved. The lightingmay also be adapted to differ depending upon a task assigned to thefirst person. As another example, the lighting may be adapted tocommunicate information concerning a status of the first cart, a healthof the first cart, a movement speed of the first cart, and/or a changein direction of the first cart. The audio source may be adapted to, forexample, communicate information concerning a status of a task assignedto the first person, a proximity of the first cart to a plurality ofpersons, and/or a status of the first cart.

The first cart may include a sensor for, at least in part, identifying adistance of the first person from the first cart, determining a positionof the first cart within the warehouse, and/or identifying an obstaclein a path of the first cart. The first cart may also include a productcode reader.

In one embodiment, the warehouse automation system also includes aworkstation for processing the products. The workstation may include arobotic arm and/or may be adapted to remove a product from the firstcart. The workstation may be, for example, a sorting station, a packingstation, a shipping station, a kitting station, a personalizationstation, or a gift wrapping station. The warehouse automation system mayalso include a display for displaying real-time performance metrics ofthe first and other persons, and/or a plurality of overhead camerasadapted to monitor the plurality of carts, the first person, andmaterial handling equipment, as well as to determine a location of eachcart.

In general, in another aspect, embodiments of the invention feature amethod for automating and improving operating productivity of awarehouse. In accordance with one embodiment of the method, a firstperson is associated with a first one of a plurality of carts fortransporting products within a warehouse and the first cart iscontrolled to lead the first person around the warehouse.

In various embodiments of this aspect of the invention, the first cartmay be moved at a speed equal to a normal pace of the first person or ata speed faster than a normal pace of the first person. The method mayalso include associating the first person with a second one of theplurality of carts at the same time that the first person is associatedwith the first cart, and/or associating a second person different fromthe first person with the first cart at (optionally) the same time thatthe first person is associated with the first cart. A task may also beassigned to the first person based upon a computed and/or stored abilityof the first person. In another embodiment, a receptacle on the firstcart is illuminated to identify the receptacle within which a product isto be placed or from which a product is to be retrieved. Optionally, thereceptacle on the first cart is illuminated differently depending upon atask assigned to the first person. In yet another embodiment, the methodincludes communicating, via an audio source, information concerning astatus of a task assigned to the first person, a proximity of the firstcart to a plurality of persons, and/or a status of the first cart. Themethod may also include displaying real-time performance metrics of thefirst and other persons.

These and other objects, along with advantages and features of theembodiments of the present invention herein disclosed, will become moreapparent through reference to the following description, theaccompanying drawings, and the claims. Furthermore, it is to beunderstood that the features of the various embodiments described hereinare not mutually exclusive and can exist in various combinations andpermutations.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention. In the followingdescription, various embodiments of the present invention are describedwith reference to the following drawings, in which:

FIG. 1 is a block diagram depicting a high-level system architecture fora warehouse automation system in accordance with one embodiment of theinvention;

FIG. 2A schematically illustrates an enhanced cart in accordance withone embodiment of the invention;

FIG. 2B schematically illustrates an enhanced cart in accordance withanother embodiment of the invention;

FIG. 3 is an exemplary graphical user interface in accordance with oneembodiment of the invention;

FIG. 4 schematically illustrates two enhanced carts in accordance withyet another embodiment of the invention and, in particular, depictsexemplary sensors on the enhanced carts;

FIG. 5 is a block diagram illustrating product flow within a warehousein accordance with one embodiment of the invention;

FIG. 6 schematically illustrates a post pick sortation station inaccordance with one embodiment of the invention;

FIG. 7 is a block diagram of a warehouse in accordance with oneembodiment of the invention; and

FIG. 8 is a table summarizing exemplary advantages of a warehouse systemthat employs an enhanced cart in accordance with one embodiment of theinvention.

DETAILED DESCRIPTION

In broad overview, embodiments of the present invention feature awarehouse automation system adapted to improve warehouse operatingproductivity. The system includes a plurality of enhanced carts fortransporting products within the warehouse and a controller. Use of theenhanced carts improves upon current warehouse systems, as the enhancedcarts have several features that improve user or associate productivity.These features can, for example, be customized to each associate and/orgive rise to gamification. Further, the enhanced carts may includefeatures to ease the process of adopting this new technology inpractice. In various embodiments, these improvements over traditionalcarts decrease the time the associate spends, for example, restocking,picking, counting, sorting, moving, and packing product into customerorders and shipments.

FIG. 1 depicts an exemplary high-level system architecture for thewarehouse automation system. In the depicted implementation, thewarehouse automation system includes a controller 10 in communicationover a network 14 with one or more control subsystems 20 disposed inrespective enhanced carts. The network 14 can provide direct or indirectwireless links among communicating devices using, for example, 802.11(Wi-Fi), Bluetooth, GSM, CDMA, or other suitable techniques. As referredto throughout this disclosure, the term “system” can include thecontroller 10, the control subsystems 20 in the enhanced carts, and/orother computing devices or subsystems that communicate or interface withany of the foregoing components to provide the functionality describedherein. For example, when it is stated herein that the “system” performsa function or accomplishes a task, it is generally meant that (eitherindividually or collectively) the controller 10, the control subsystems20 in the enhanced carts, and/or the other computing devices orsubsystems perform the function or accomplish the task. One of ordinaryskill in the art will appreciate that various configurations of thewarehouse automation system are possible.

The controller 10 and the control subsystems 20 can include suitablehardware and software to provide the functionality described herein. Forexample, the controller 10 and the control subsystems 20 can includeappropriate transmitters and receivers (e.g., Wi-Fi network adapters,Bluetooth radios, etc.) to communicate with each other and/or over thenetwork 14. The controller 10 and the control subsystems 20 can alsoinclude general purpose computing devices, each in the form of acomputer including a processing unit, a system memory, and a system busthat couples various system components including the system memory tothe processing unit, and/or embedded devices or other special purposelogic circuitry, e.g., an FPGA (field programmable gate array) or anASIC (application-specific integrated circuit). Computing devicesincluded in the controller 10 and the control subsystems 20 can utilizesoftware processing modules stored in a memory and executed on aprocessor. Processors suitable for the execution of a computer programinclude, by way of example, both general and special purposemicroprocessors. Generally, a processor receives instructions and datafrom a read-only memory or a random access memory or both. Informationcarriers suitable for embodying computer program instructions and datainclude all forms of non-volatile memory including, by way of example,semiconductor memory devices, e.g., EPROM, EEPROM, and flash memorydevices; magnetic disks, e.g., internal hard disks or removable disks;magneto-optical disks; and CD-ROM and DVD-ROM disks.

By way of illustration, the software modules can be in the form of oneor more suitable programming languages, which are converted to machinelanguage or object code to allow the processor or processors to executethe instructions. The software can be in the form of a standaloneapplication, implemented in a suitable programming language orframework. In some implementations, such software executes on a customor commercially available operating system, such as the MicrosoftWindows® operating systems, the Apple OS X® operating systems, the AppleiOS® platform, the Google Android™ platform, the Linux® operating systemand other variants of UNIX® operating systems, and the like.Additionally or alternatively, some or all of the functionalitydescribed herein can be performed remotely, in the cloud, or viasoftware-as-a-service.

A. Enhanced Carts

FIG. 2A depicts an enhanced cart system 100 in accordance with oneembodiment of the invention. As illustrated, one or more enhanced carts102, often referred to in the industry as picking carts, can workalongside one or more warehouse associates 104 to move inventory arounda warehouse. The enhanced carts 102 are intended to assist in mostwarehouse tasks, such as picking, re-stocking, moving, sorting, andcounting or verifying products. These carts 102 can display informationto the associate 104 through the use of a screen 106 and/or onboardvisual and/or audible indicators that improve the performance of theassociates 104. The carts 102 need not necessarily be assigned to onespecific associate 104. Rather, there can be multiple carts 102 thathelp an associate 104 throughout the day, optionally at the same time.Likewise, a single cart 102 may work with multiple associates 104 in asingle day, optionally at the same time. The system may track thelocation of each cart 102 and the identity of each associate 104completing the task at hand. The system may also store relevanttransaction information (e.g., product, location, and associates) withinthe system for further analysis.

B. Enhanced Carts' Carrying Capability

Referring still to FIG. 2A, the enhanced carts 102 may be configured tocarry one or many similar or distinct storage receptacles 108, often inthe form of totes or boxes, that can be used to hold one or moredifferent products. These storage receptacles 108 may be removable fromthe enhanced cart 102. In some cases, each receptacle 108 can be used asa separate picking location (i.e., one receptacle 108 is a singleorder). In other cases, the receptacles 108 can be used for batchpicking (i.e., each receptacle 108 can contain multiple complete orpartial orders). Each receptacle 108 may be assigned to one or manydifferent stations for post-pick sortation and processing. In oneembodiment, one or more of the receptacles 108 are dedicated to batchpicking of multiple types of products and another one or morereceptacles 108 are dedicated to picking multiple quantities of a singleproduct (e.g., for orders that only have one item). This singletonpicking allows the warehouse to skip secondary sortation and deliverproducts directly to a packaging station. In another embodiment, one ormore of the receptacles 108 are assigned to order picking (e.g., forpotentially time sensitive orders) and one or more of the receptacles108 are assigned to batch picking (e.g., for lower cost or less timesensitive orders). In yet another embodiment, one or more of thereceptacles 108 carry product that will be used to re-stock product intostorage locations. Another option is for the enhanced cart 102 to moveproduct and/or shipments throughout the warehouse as needed betweendifferent stations, such as packing and shipping stations. In yetanother implementation, one or more of the receptacles 108 is left emptyto assist in counting product into and then back out of the receptacle108 as part of a cycle count task regularly carried out in warehousesfor inventory management. The tasks may be completed in a mode dedicatedto one task type or interleaved across different task types. Forexample, an associate 104 may be picking products into receptacle “one”on the enhanced cart 102 and then be told to grab products fromreceptacle “two” on the enhanced cart 102 and put them away in the sameaisle.

C. Off-Screen User Interface

Most systems today rely heavily on a screen for their user interface.The system described herein includes a screen 106 and further features asignificant amount of user interface/user experience away from thescreen 106. For example, lighting on the enhanced cart 102 may be usedto light up the source and/or the destination of any products beingplaced into or taken out of the cart's storage receptacles 108. FIG. 2Ashows lighting places 110 at the rear of the cart 102 similar to cartail lights and also lights 112 below each storage receptacle 108location. This lighting may change color based upon the task, so thatthe associate 104 has to look minimally or not at all at the screen 106for instructions. Any storage receptacle 108 that spans the enhancedcart 102 may have lighting 112 that can illuminate on either side,either for visibility from any side or as an indicator as to which sideof the enhanced cart 102 the product should be picked from or placed to.The lighting 112 may be finely divisible into many segments and can beconfigured to illuminate one or many storage receptacles 108 withoutphysically changing the lights. If there is only one receptacle 108, theentire light indicator 112 may light up. If there are two or morestorage units 108, then the lighting indicator 112 may be divided intotwo or more segments, so that each receptacle 108 can be individuallyindicated. LED strip lighting or other suitable lighting may beutilized.

In some embodiments, one or more action buttons are present on the cart102 and allow the associate 104 to confirm actions such as putting anitem into a storage location 108, such as a tote or bin, or to pause thecart 102. In some embodiments, these buttons are placed on a continuous,touchable surface near the edges of the storage locations 108 on theenhanced cart 102.

In addition to storage receptacle 108 identification, lighting may beused to indicate cart status or health, speed of movement, intendedchange in direction, or other information useful for the interactionwith associates 104 in completing their tasks.

The visual user interface may be complemented with audio instructions toaid the associate 104. This is often helpful where the associate 104does not have sight of the screen 106 or is visually impaired, in aidingwith communications with a supervisor or a remote help desk to assistthe associate 104 through his/her task, or in coordination with videoconferencing technologies embedded in a graphical user interface thatmay be used in interacting with a remote help desk or other assistance.In addition, in some embodiments, the audio source communicatesinformation concerning the status of a task assigned to the associate104, the proximity of the enhanced cart 102 to one or more associates104, and/or the status of the enhanced cart 102.

D. On-Screen User Interface

Some of the user interface may be presented on a screen that shows theassociate 104 working with the system information to help the associate104 reduce the time it takes to complete his/her tasks in the warehouse.Such a graphical user interface screen may be located on the mobile cart102 (as is the case, for example, with the exemplary screen 106 depictedin FIG. 2A) or the graphical user interface screen may be in theassociate's possession (e.g., on a mobile computer, such as a tablet orsmartphone, or on a wrist mounted screen).

The associate 104 may employ a wireless headset, phone, touchscreen, orother computer (hereinafter referred to as a “mobile device”). In someembodiments, when an associate 104 switches to a new cart 102, thesystem will automatically switch the mobile device, because the systemknows in advance to which cart 102 the associate 104 will be paired. Inaddition to the fully automated switching, the cart 102 may require thatthe associate 104 confirm the switch by interacting with the old cart,the new cart, and/or the mobile device. As an example, an associate 104using a first cart may switch to a second cart and at that time theassociate's mobile device disconnects from the first cart and connectsto the second cart.

The screen employed by the associate 104 may provide context sensitiveinformation that takes into account some combination of one or more ofthe following information: the cart's and/or associate's physicallocation in the warehouse, the current tasks they are working on, timebetween tasks, priorities in the warehouse, location and storagedetails, physical location of product in the warehouse, and previousperformance information of that associate 104.

Information may be displayed that allows the associate 104 to quicklyidentify what task(s) he/she is supposed to accomplish and whatproduct(s) he/she is supposed to operate on, as well as the source andthe destination of the products for the current task.

By displaying information to the associate 104 (e.g., on the cart'sscreen 106 or on a mobile device screen) while the cart 102 is movingbetween tasks, the time to complete the next task may be shortenedadvantageously, as the associate 104 has less information to processupon arrival at the location of each task. Tasks completed upon arrivalmay include picking or replenishment of items in the warehouse. In someembodiments, information displayed while moving or transitioning betweentasks includes the distance to the next task, the location of the nexttask, the item to grab, the quantity to grab, and real time informationlike productivity rates.

In addition to displaying information in advance of one task, the screen106 on the enhanced cart 102 and/or a mobile device screen may alsodisplay information on the next string of tasks. This allows theassociate 104 to become aware of all tasks in an area and to optimizehis or her movement to complete these tasks without looking at thescreen for each step.

FIG. 2B is an alternative embodiment of the enhanced cart 102, and isshown (for ease of understanding) without the storage receptacles 108being present. As before, the enhanced cart 102 includes the screen 106and lighting indicators 110, 112. In operation, the storage receptacles108 may be present on the enhanced cart 102 depicted in FIG. 2B. Asillustrated, a front end of the cart 102 may define a cutout 156. Theremay be one or more sensors (e.g., light detecting and ranging sensors)housed within the cutout 156. The cutout 156 permits the sensor(s) toview and detect objects in front of and to the side of (e.g., more than180° around) the cart 102.

FIG. 3 shows an exemplary graphical user interface that may be displayedon the screen 106 of the enhanced cart 102 or on a mobile device screen.A first display 346 shows the items to pick 348 and the direction ofthose items 350. A second display 352 shows the bins 354 from which eachitem 348 needs to be picked. The display 352 may also contain additionalinformation, such as the locations of bins of the following items to bepicked and the number of each item to be picked.

E. Associate Motivational Enhancement

The associates 104 working at a warehouse often have physicallydifficult and mentally tedious work. In various embodiments, the systemdescribed herein gets the best productivity out of each associate 104and motivates them in a number of ways. One way is by keeping theassociates 104 mentally engaged and focused on their work—this reduceserror rates and increases productivity. Using gamification methods tocreate a competitive environment can achieve many of these goals. Bykeeping real-time score, daily/weekly/monthly high scores, orperformance trends, associates 104 compete against one another and/orthemselves. In some warehouse operations, a portion of the associate'scompensation is tied to his/her individual performance, based uponhitting or exceeding certain rates or other performance metrics. In themost widely used systems, associates 104 only learn how well they areperforming at the end of their shift or the end of the week. Inembodiments of the system described herein, the associates' performancesare shown in real time (e.g., via the screen 106 or via another display,such as an overhead display) so that they remain informed and motivatedto hit various individual and team goals.

In one embodiment, the system also captures the rate that the associates104 move through the warehouse. The system has the ability to learn thebasic pace of an associate 104 and to use that data to establish eachassociate's “normal pace.” The system may move the cart 102 through thewarehouse at the associate's “normal pace” or, to improve productivityrates, the system may prompt the cart 102 to move slightly faster thanthe “normal pace” for the associate, essentially “pulling” him/herthrough his/her work from the front. For example, the cart 102 may move5%, 10%, 15%, or 20% faster or more. With reference to FIG. 4, there mayalso be a sensor 216 at the rear of the cart 102 to identify thedistance of the associate 104 from the cart 102, allowing the cart 102to stop or slow down if the pace is too fast and the associate 104 isnot keeping up.

In greater detail, the system may adapt the enhanced cart 102 to thepace that optimizes the rate of the associate 104 based on learnedparameters. In some instances, the enhanced cart 102 will move faster orslower depending on which associate 104 is paired to the cart 102. Inaddition, the enhanced cart 102 might not stop for a task, such aspicking, but instead may just slow down enough to allow the associate104 to complete the task.

In one embodiment, the system knows when the enhanced carts 102 areworking with a particular associate 104. As such, the associate'sinteraction with the cart 102 and the system can be personalized to makethe associate 104 more efficient and more content. In variousembodiments, this includes changing the language, voice (e.g., male orfemale, accent, etc.), or other features based on various associateneeds or disabilities, such as color blindness, as the cart 102 handsoff between various associates 104 or as the associate 104 transitionsbetween carts.

F. Enhanced Cart Sensors

With reference still to FIG. 4, in one embodiment the enhanced cart 102has a number of sensors 214, 216 that it uses to navigate around thewarehouse and interact with associates 104 and product within it. Forexample, the enhanced cart 102 may have a sensor 214 located at a frontof the cart 102 and/or a sensor 216 located at the rear of the cart 102.Sensors, such as laser ranging, structured light sensors or justcameras, may be used to locate the enhanced cart 102 within thewarehouse and detect possible obstacles in the cart's way. Techniques,such as Simultaneous Localization and Mapping (SLAM), can be used tocreate or enhance digital maps of the warehouse and to locate the carts102 within the warehouse. This information may be shared betweenmultiple enhanced carts 102 in the warehouse, so that they continuallyor periodically receive updated information about changes in thewarehouse.

The enhanced cart 102 may also use these sensors 214, 216 to localizeitself by, for example, detecting visual images including words,numbers, and/or any two dimensional or three dimensional codes used in awarehouse. Once a labeling code has been identified, its location in thewarehouse may be looked up and used to augment other locationinformation for the enhanced cart 102. This information can also be usedin reverse. For example, once an enhanced cart 102 knows its location,it can use the location information to map key points of interest in awarehouse, such as bins, travel paths, charging locations, and meetingpoints.

Additional sensors, such as laser ranging sensors, thermal imagingsensors, structured light sensors, or video, may be used to detect thelocation of the associates 104 that the system is assisting. This allowsthe system to slow down the cart 102 or send an alert or notification tothe associate 104 or management if the associate 104 falls too farbehind or leaves the proximity of the enhanced cart 102.

The enhanced cart 102 may also have one or more product code readers218. These may be used to read a one dimensional code, such as UPCbarcodes, a two dimensional code, such as QR codes, or both. The cart102 may use the product code reader 218 to verify the product codeduring picks, re-stocking, and counting. Furthermore, the enhanced cart102 may read barcodes of products or storage locations as it moves pastthem, unrelated to the active workflow. This may be used to helpidentify the cart's location in the warehouse, verify the location ofproducts in the warehouse, or complete cycle counting tasks of productsor empty product locations. Further, the system may monitor productlocations and can sense if they have been modified, triggering a manualverification if the modification was unexpected. This can be helpful incorrecting for mispicked items or possible theft.

In some embodiments, the enhanced cart 102 has a weight sensor undereach storage receptacle 108 to measure the change of weight when an itemof a known or unknown weight is put onto the cart 102. This weightsensor may detect the difference and confirm that the item was placed inthe correct location. If the weight sensor does not detect a change inweight or does not detect the correct change in weight, it may flag thatan item was not placed in the correct storage receptacle 108 on the cart102 or that an incorrect item was placed in the storage receptacle 108on the cart 102.

In some embodiments, the enhanced cart 102 has a camera or image sensorlooking at certain locations on the enhanced cart 102 and/or into thestorage receptacles 108 positioned on the cart 102. This sensor canconfirm if an item has been placed into or taken from the storagereceptacle 108 on the cart 102. In one embodiment, the system looks fora change in the location image before and after an expected action. Asanother example, object recognition may be used to detect if an item hasbeen placed into or has been taken out of a storage receptacle 108.Object recognition may allow for a higher level of accuracy.

Some embodiments of the enhanced cart 102 include a weight sensor, acamera or image sensor, a hall effect sensor (e.g., using magnets), orsome sort of electrically transmitting or passive response tag to detectthe placement and removal of storage receptacles 108 on the enhancedcart 102.

G. Enhanced Cart Collaboration with Associates

The enhanced carts 102, especially if they are self-powered, may createinitial hesitation for associates 104 in a warehouse, regardless of howsafe they are. This can be distracting to the associates 104 or causethem to interact cautiously with the cart 102, not knowing how or whenthe cart 102 moves. This hesitation may have a negative impact onproductivity. To address this concern, the cart's movements may be mademore obvious by giving visual feedback to the associates 104 when thecarts 102 are starting to move, stopping, and/or turning. In addition,to reduce any learning curve, the carts mimic, in one embodiment,something that most people are familiar with: the automobile. In onesuch embodiment, the enhanced cart 102 is configured to look and act asmuch as possible as a conventional car. This includes blinkers, brakelights, and other visual and audible cues that make the associates 104comfortable that they understand what to expect from the enhanced cart102.

H. System Adapts to Associates

Different associates 104 have different skill levels, speeds, heights,and other characteristics that effect which tasks they perform best, aswell as how to best get them to perform those tasks. Their skills mayalso evolve as they learn and have more experience at one or more tasksor other operations. In one embodiment, the system described hereinlearns, through machine learning techniques such as neural networks,support vector machines, and others, the workflow between variousassociates 104 and optimizes which associates 104 are assigned to whichtasks. For instance, the system can learn characteristics such as thetime it takes to access product that is on different level shelves(e.g., due to an associate's height), or how product weight affects anassociate's picking rate (e.g., due to the associate's strength), andthen assigns tasks to associates 104 who are best able and quickest atperforming these tasks. As previously discussed, the system may alsolearn an individual associate's walking speed to set the speed of theenhanced cart 102. Another issue addressed by the system isunderstanding the real cost of interleaving (i.e., mixing multiple tasktypes like picking and re-stocking), so as to create the right mix oftasks to optimize associate performance.

I. Product Flow

FIG. 5 is a block diagram depicting the flow of product through awarehouse that ships customer orders, in accordance with one embodimentof the invention. In various embodiments of the system depicted in FIG.5, enhanced carts 102 collaborate with warehouse associates 104 to helpthe associates 104 in their tasks and to move product between differentareas of the warehouse. These enhanced carts 102 may be propelled bymotors to transport product around the warehouse and reduce the amountof time people would otherwise spend manually moving product in anon-automated warehouse.

I.1. Inbound Product

In the exemplary system depicted in FIG. 5, there are three options forwhere inbound product can be directed (i.e., paths A, B, and C). Invarious embodiments, the enhanced carts 102 direct and transport theproduct from inbound to each of these areas where the product is stored.The “Active, Each Pick Area” 320 stores product that is ready to bepicked for customer orders. The “Reserve Bulk Storage Area” 322 holdsproduct that may be too large to fit in the active area 320 or that isreserve quantities for product stored in the “Active, Each Pick Area”320. Product that goes through the “Cross Dock” area 324 is not storedin the warehouse and is in transit to its final destination. Thisproduct may be either merged with other product in the “Packing” area326 via path H or sent directly to the outbound area 328 via path I.

I.2. Outbound Product

When a customer order is assigned to the warehouse, the system maydetermine the optimal resource to pick the item—whether it be anassociate 104 with an enhanced cart 102, an associate 104 with no cart,a forklift, or other material handling vehicle or apparatus. The productmight be stored in the “Active. Each Pick Area” 320 or in the “ReserveBulk, Storage Area” 322. If the product is in the “Active, Each PickArea” 320, the product may be picked and transported to either “PackSortation” 330 (via path D) or “Packing” area 326 (via path F). “PackSortation” 330 is the area where product is merged into discretecustomer orders. If this sortation does not need to happen, product maybe moved directly to “Packing” area 326. If the product is in the“Reserve Bulk Storage Area” 322, it may be moved into the “Active. EachPick Area” 320 via path E or sent to the “Packing” area 326 via path G.Once items are sorted into discrete orders (via process J), they mayneed additional sortation by transportation carrier, destination zone,or delivery method. “Ship Sortation” 332 may occur (via process K),after which the orders are loaded in the outbound area 328 onto trucksor other vehicles for shipment to customers.

The system can support any number of permutations depicted in FIG. 5 andcan be configured based on the unique needs of the warehouse. Forexample, using software and hardware (e.g., a controller 10, asdescribed above, which may be part of the overall system describedherein), the enhanced carts 102 can be configured to transport one ormany storage receptacles 108, such as a totes or customer shipments,through different simultaneous processes, such as batch pick (i.e.,groups of products) and discrete order pick (i.e., groups of completeorders).

As explained above, some enhanced carts 102 are autonomous and leadassociates 104 around the warehouse. In various embodiments, theenhanced carts 102 supplement associate workflow with on and off screeninterfaces to make the associate 104 more productive by reducing thetime to complete an assigned task and reducing the downtime betweentasks. These interfaces can also motivate the associate 104 to workfaster by displaying real-time and historical performance data and/or bygamifying the workflows to make the associate's job more interesting. Insome embodiments, the system uses historical data to adapt to eachassociate 104.

The system moves product to different workstations forprocessing—including packing, shipping, kitting, personalization, giftwrap, and other stations. After processing, products may be combinedinto orders for shipment. The system can be used to sort shipments byground or air delivery as determined by customer need or paid level ofservice. Depending on the shape and characteristics of the product, thesystem may also interface with downstream sortation automation tofurther reduce the amount of labor needed to process an order.

J. Post-Pick Sortation

FIG. 6 schematically illustrates a post pick sortation station inaccordance with one embodiment of the invention. After a warehouseassociate 104 picks into the enhanced cart 102, the cart 102 may be sentto multiple stations for post pick sortation. At some stations, thesortation is done by associates 104. At other stations, a robotic arm434 picks product items 436, 438 from a storage area 108 on the enhancedcart 102 and places them into specific bins 440 (e.g., on a sortationwall 442) assigned to unique customer orders. In FIG. 6, the diamonds436 and triangles 438 represent different product being moved by therobotic arm 434 into the sortation wall 442. After the final item forthe customer order is placed into the wall 442, an associate 104 isnotified and the order is packed out for shipment. This allows the “PackSortation” process 330 depicted in FIG. 5 to be automated. In someembodiments, the enhanced cart 102 makes multiple stops at differentstations of this type, or multiple enhanced carts 102 stop at thesestations to complete customer orders or shipments.

K. Multiple Enhanced Cart Coordination

In various embodiments, there are multiple enhanced carts 102 working inthe same warehouse and there is a benefit to having the systemcoordinate the carts 102 to work better than they would by themselves.Navigation information, such as detected changes in the warehouselayout, information on obstacles, and location of associates 104 andcarts 102 or other tracked equipment, can be shared between the enhancedcarts 102, allowing them to make better navigation choices. In oneembodiment, the enhanced carts 102 are given strong suggestions or rulesthat allow them to navigate congested warehouse floor locations oraisles more effectively. This may be done by assigning directionality tovarious aisles and open areas so that the computation required tonavigate congested areas is simplified.

In one embodiment, the external controller 10 also helps coordinate themultiple enhanced carts 102 that are interacting with one or moreassociates 104. Cart position planning may be used to help the associate104 stay busy. For example, when one cart 102 is full, or otherwisefinished with its work, a second cart 102 is immediately available forthe associate 104. This minimizes transition time between carts 102,keeping associate utilization high. The associate 104 may also work withmultiple carts 102 simultaneously, for example on opposite sides of theaisle, to increase the amount of work completed. The system may alsotell the associate 104 to meet an enhanced cart 102 at a predeterminedand/or designated location.

The system controller 10 can also interact with other material handlingequipment, such as forklifts, which can be tracked and which may beautonomous or semi-autonomous. This mobile equipment may be coordinatedby the system so that it is more efficiently routed and scheduled withthe enhanced carts 102. If it is not possible or feasible to assigntasks to some or all of the other equipment, their position in thewarehouse may be used to help route the enhanced carts 102 so as tolimit or prevent congestion or possible collisions.

In one embodiment, the system works with automatic picking and placingsystems. The system may also ensure that the appropriate resource isused to complete the task most efficiently. For example, if a roboticarm and the enhanced cart 102 reduces the cost (e.g., time, accuracy,etc.) of the pick, the combination is assigned to complete the task.

L. Assigning Different Enhanced Carts Based on Workload

In one embodiment, the system supports carts 102 having differentconfigurations, such as the size, capacity, and/or location of thereceptacles 108. For example, the system may maintain the differentconfigurations of enhanced carts 102 and assign the right configurationto support the task attributes of product, associate, or task type(e.g., count, pick, re-stock, etc.).

M. Enhanced Carts' Mobility

Although not required, the system generally performs better if theenhanced carts 102 move under their own power. This reduces the amountof time walked by the associates 104 and reduces the amount of work theassociate 104 would normally have to do when pushing or pulling the cart102. See the table in FIG. 8, discussed further below. In addition, thecart 102 may guide one or more associates 104 to the correct locationfor their work and then stop, slow down, or drive (e.g., at crawl speed)by the location of the task, as appropriate.

N. Asset Tracking with Cameras

In various embodiments, specialized overhead cameras are used to trackthe carts 102, associates 104, forklifts, and other mobile equipment.These overhead cameras can look for identifying marks placed on trackedobjects. FIG. 7 shows a schematic warehouse layout and the location ofoverhead cameras 544 (depicted as stars 544 in FIG. 7), in accordancewith one embodiment of the invention. The identifying marks may benatural shapes of the objects or a special pattern that is either in thevisible or invisible spectrum. The specialized cameras 544 can thentrack the various objects and convert their positions into physicallocations. This information may be collected from a series of cameras544. In some embodiments, these cameras 544 are located near theceiling. The cameras 544 can collect image data independently from eachother and often overlap in their coverage area. Various approaches maybe employed to merge multiple cameras' data streams. A first approach isto take each set of image data and merge them together, and to look forpatterns in the resulting meta-image. A second method, which is usuallycomputationally superior, is to track each item with a single camera 544and then combine the location information together in a weighted form toget final location information. Although it is possible to track itemswith cameras 544 that do not have somewhat overlapping images, thequality of tracking data is generally superior if there is more overlap.In addition, subsampling techniques can be used to get sub-pixelaccuracy of a location that is more accurate than the base resolution ofthe cameras 544.

O. Enhanced Carts Leading

In various embodiments, the system knows the location of enhanced carts102 within the warehouse and, at times, the enhanced carts 102 leadassociates 104 around the shelving aisles and other areas of thewarehouse. The enhanced carts 102 move at a speed determined by thesystem. By leading the associate 104, the enhanced cart 102 can preventwrong turns and stop in specific locations next to workstations or instorage locations to increase associate 104 productivity. If associates104 do not keep pace with the cart 102, the system can adapt and storethis information for analysis and performance monitoring. In variousembodiments, the enhanced cart 102 uses audio and visual indicators tomake the enhanced cart 102 easier to follow for the associate 104, sothat the associate 104 can anticipate the cart's movement.

P. Exemplary Advantages of the System Described Herein

The pick process may be modeled as seven steps—walk to the bin, find thebin, search for the product, grab the product, confirm the product iscorrect, place the product into the receptacle 108, and request the nexttask. In general, the system reduces the time of six of these steps—allexcept grab the product. In FIG. 8, the proposed time savings isprojected for each of the seven steps in the typical batch pick betweena manual cart pick and an enhanced cart pick.

Walk to Bin: A typical cart pick operation is calculated to spend 15seconds per pick walking to the bin. By aggregating picks into batchpicks, and keeping the associate 104 in the aisles and not in otherareas, like cart 102 turnover, the system can reduce 40% of the walkingan associate 104 does.

Find Bin: When the associate 104 is in the location of a bin, he/she hasto find the bin in the racking. The system can reduce or eliminate thesearch time by showing, for example on the screen 106, an image of thelocation and by highlighting the location in relation to other bins inthe area.

The enhanced cart 102 may stop in a position relative to the bin wherework is being performed to minimize the associate's time moving goods toand from the enhanced cart 102 and the bin.

Search for Item: The associate 104 can be shown, for example on thescreen 106, an image of the product, a description, the position of thescannable barcode (for verification), and the quantity to help find theitem in the bin faster.

Grab Item: In various embodiments, this step is not automated oraffected, though a robotic arm could be used to grasp a heavy orcumbersome item, in some embodiments.

Confirm Pick: After the product is picked from the bin, a fixed scanner218 on the enhanced cart 102 can scan the barcode to verify that theitem is correct. This process can be faster than a traditionaloperation, where the associate 104 has to hold a scanner in one hand andthe product in the other hand, find the bar code on the product, andtrigger the scan to take place.

Place Item: The next step is for the associate 104 to place the iteminto the correct storage receptacle 108 on the cart 102. Using lights112 and other interfaces and on-screen 106 images, the process can besped up over a traditional operation, where the associate 104 has tofind the location using a printed slip or location on a graphicalinterface.

Next task: After the item is placed in the storage receptacle 108 on thecart 102, the cart 102 can automatically transition to the next task. Inone embodiment, the cart 102 either resumes moving forward to anotherbin location or instructs the associate 104 to transition to another binor cart 102 in the general area. This automatic transition reduces thetime between tasks and improves utilization.

In the example presented in FIG. 8, a 33% reduction in cycle time,corresponding to a 50% increase in productivity, is realized.

The terms and expressions employed herein are used as terms andexpressions of description and not of limitation and there is nointention, in the use of such terms and expressions, of excluding anyequivalents of the features shown and described or portions thereof. Inaddition, having described certain embodiments of the invention, it willbe apparent to those of ordinary skill in the art that other embodimentsincorporating the concepts disclosed herein may be used withoutdeparting from the spirit and scope of the invention. The structuralfeatures and functions of the various embodiments may be arranged invarious combinations and permutations, and all are considered to bewithin the scope of the disclosed invention. Unless otherwisenecessitated, recited steps in the various methods may be performed inany order and certain steps may be performed substantiallysimultaneously. Accordingly, the described embodiments are to beconsidered in all respects as only illustrative and not restrictive.Furthermore, the configurations described herein are intended asillustrative and in no way limiting. Similarly, although physicalexplanations have been provided for explanatory purposes, there is nointent to be bound by any particular theory or mechanism, or to limitthe claims in accordance therewith.

What is claimed is:
 1. An automation system adapted to improve operatingproductivity within an area where products are stored, the systemcomprising: a plurality of carts for transporting products within thearea; and a controller adapted to associate a first one of the pluralityof carts with a first person and to control and automatically move thefirst cart at a controller determined speed to lead the first personaround the area.
 2. The system of claim 1, wherein the controllerdetermined speed is selected from the group consisting of a speed equalto a normal pace of the first person and a speed faster than a normalpace of the first person.
 3. The system of claim 1, wherein thecontroller is further adapted to set settings of the first cart personalto the first person and to set settings of the first cart personal to asecond person different from the first person when the second person isassociated with the first cart.
 4. The system of claim 1, wherein thecontroller is further adapted to assign a task to the first person basedupon an ability of the first person.
 5. The system of claim 1, whereinthe controller is further adapted to associate a second one of theplurality of carts with the first person at the same time that the firstcart is associated with the first person.
 6. The system of claim 1,wherein the controller is further adapted to associate the first cartwith a second person different from the first person at the same timethat the first cart is associated with the first person.
 7. The systemof claim 1, wherein the first cart comprises at least one receptacle forreceiving a product.
 8. The system of claim 1, wherein the first cartcomprises a motor for propelling the first cart.
 9. The system of claim1, wherein the first cart comprises at least one of an on-screeninterface and an off-screen interface for communicating information tothe first person.
 10. The system of claim 9, wherein the first cartcomprises the on-screen interface and further wherein the on-screeninterface is adapted to communicate information concerning at least oneof a physical location of the first cart within the area, a physicallocation of certain product within the area, a current task assigned tothe first person, time between various tasks, priorities in the area,and performance of the first person.
 11. The system of claim 9, whereinthe first cart comprises the off-screen interface and further whereinthe off-screen interface comprises at least one of lighting and an audiosource.
 12. The system of claim 11, wherein the first cart comprises thelighting and further wherein the lighting is adapted to identify areceptacle on the first cart within which a product is to be placed orfrom which a product is to be retrieved.
 13. The system of claim 11,wherein the first cart comprises the lighting and further wherein thelighting is adapted to differ depending upon a task assigned to thefirst person.
 14. The system of claim 11, wherein the first cartcomprises the lighting and further wherein the lighting is adapted tocommunicate information concerning at least one of a status of the firstcart, a health of the first cart, a movement speed of the first cart,and a change in direction of the first cart.
 15. The system of claim 11,wherein the first cart comprises the audio source and further whereinthe audio source is adapted to communicate information concerning atleast one of a status of a task assigned to the first person, aproximity of the first cart to a plurality of persons, and a status ofthe first cart.
 16. The system of claim 1, wherein the first cartcomprises a sensor for, at least in part, at least one of identifying adistance of the first person from the first cart, determining a positionof the first cart within the area, and identifying an obstacle in a pathof the first cart.
 17. The system of claim 1 further comprising at leastone workstation for processing the products.
 18. The system of claim 1further comprising a display for displaying real-time performancemetrics of the first and other persons.
 19. The system of claim 1further comprising a plurality of overhead cameras adapted to (i)monitor the plurality of carts, the first person, and material handlingequipment, and (ii) determine a location of each cart.
 20. The system ofclaim 1, wherein the area comprises a warehouse.
 21. A method forautomating and improving operating productivity within an area whereproducts are stored, the method comprising the steps of: associating afirst person with a first one of a plurality of carts for transportingproducts within the area; determining, with a controller, a speed atwhich to move the first cart; and controlling and automatically movingthe first cart at the controller determined speed to lead the firstperson around the area.
 22. The method of claim 21, wherein thecontroller determined speed is selected from the group consisting of aspeed equal to a normal pace of the first person and a speed faster thana normal pace of the first person.
 23. The method of claim 21 furthercomprising associating the first person with a second one of theplurality of carts at the same time that the first person is associatedwith the first cart.
 24. The method of claim 21 further comprisingassociating a second person different from the first person with thefirst cart at the same time that the first person is associated with thefirst cart.
 25. The method of claim 21 further comprising assigning atask to the first person based upon an ability of the first person. 26.The method of claim 21 further comprising illuminating a receptacle onthe first cart to identify the receptacle within which a product is tobe placed or from which a product is to be retrieved.
 27. The method ofclaim 21 further comprising illuminating a receptacle on the first cartdifferently depending upon a task assigned to the first person.
 28. Themethod of claim 21, further comprising communicating, via an audiosource, information concerning at least one of a status of a taskassigned to the first person, a proximity of the first cart to aplurality of persons, and a status of the first cart.
 29. The method ofclaim 21, further comprising displaying real-time performance metrics ofthe first and other persons.
 30. The method of claim 21, wherein thearea comprises a warehouse.